Gravity-fed in-line continuous processing system and method

ABSTRACT

A gravity-fed in-line continuous processing system includes at least one processing chamber disposed between a first load lock and a second load lock. The second load lock is disposed lower than the first load lock. A first device isolates the processing chamber from the first load lock. A second device isolates the processing chamber from the second load lock. There is at least one track through the processing chamber and the first and second load locks. The track is structured and arranged such that an article slides thereon under the force of gravity.

RELATED APPLICATIONS

This application is a Continuation of prior U.S. patent application Ser.No. 10/400,775 filed Mar. 27, 2003 which claims priority of and isrelated to U.S. Provisional Patent Application Serial No. 60/368,818,filed Mar. 29, 2002. This application is also related to the U.S. patentapplication entitled ROTARY BARREL GATE VALVE, filed on even dateherewith and hereby incorporated by reference herein, and which alsoclaims priority to U.S. Provisional Patent Application Serial No.60/368,818 filed Mar. 29, 2002.

FIELD OF THE INVENTION

This invention relates to a gravity-fed in-line processing system usefulfor, inter alia, rapidly coating plastic substrates such as plasticflatware and cellular telephone housings.

BACKGROUND OF THE INVENTION

Conventional systems and methods of applying coatings to substrates suchas metallizing insulative substrates include electroplating, electrolessplating, painting, arc-spray, evaporative vacuum metallization, andsputter vacuum metallization. These systems and processes are usuallybatch oriented. Typical batch oriented systems require parts orsubstrates to be placed on racks for insertion into a batch chamber. Thebatch chamber door is opened, a rack of parts is inserted into thechamber, and the door is then closed and sealed. Thereafter, coatingtakes place, and after coating, the batch chamber door is again opened,and the rack of parts is removed manually and unloaded.

One disadvantage of batch oriented production systems is that during thecoating process, other operations cease, creating down time. Also, thecycle time is long, and large production run volumes are required forthe system to be cost effective. Batch oriented systems result in largework-in-process inventories and a large number of at-risk parts beforeprocess quality can be assessed.

Some of these disadvantages and limitations may be overcome by so-called“in-line” systems that integrate vacuum metallization “in-line” with aparts molding machine. However, conventional systems are often expensiveand complex. Moreover, such systems often include conveyors, robot armswithin the system, and/or gates with valves and seals that utilize upand down and/or sliding motion which are subject to excess wear,malfunction and necessitate frequent replacement of parts over the lifeof the system. The conveyors, and robot arms within the system, can alsocontaminate the highly sensitive vacuum chambers.

BRIEF SUMMARY OF THE INVENTION

It is therefore an object of this invention to provide an improvedsystem for applying coatings to substrates and particularly formetallizing plastic parts.

It is a further object of this invention to provide a truly in-linemetallizing system that may be physically located adjacent a partsmolding machine.

It is a further object of this invention to provide such a system thatis rapid, automated, and continuous, with reduced cycle time and reduceddown time.

It is a further object of this invention to provide such a system whicheliminates the need for a conveyor or a robot arm within the system.

It is a further object of this invention to provide such a system withimproved and more robust gates or valves.

This invention results from the realization that an improved, faster,more robust, higher quality and more reliable in-line metallizationprocessing system can be achieved with a system that utilizes gravityinstead of mechanical conveyors, or robot arms within, and whichutilizes rotary barrel gate valves in place of conventional gates andvalves, and which may be located adjacent a molding machine.

This invention features a gravity-fed in-line continuous processingsystem including at least one processing chamber disposed between afirst load lock and a second load lock, with the second load lockdisposed lower than the first load lock. The system may include a firstdevice for isolating the processing chamber from the first load lock, asecond device for isolating the processing chamber from the second loadlock, and at least one track through the processing chamber and thefirst and second load locks, with the track structured and arranged suchthat an article slides thereon under the force of gravity.

In one embodiment, the processing chamber, the first load lock and thesecond load lock may all be angled with respect to the horizontal, orthe track may be angled with respect to the horizontal. The track, theprocessing chamber, the first load lock and the second load lock, or anycombination thereof, may be angled with respect to the horizontal. Theangle with respect to the horizontal may be greater than 33° but lessthan 43°. The angle with respect to the horizontal may be about 40°. Thefirst load lock may be an input load lock, and the second load lock maybe an output load lock. The first device may be structured and arrangedto prevent the article from sliding under the force of gravity when thefirst device is closed. The second device may be structured and arrangedto prevent the article from sliding under the force of gravity when thesecond device is closed. The first device may be structured and arrangedto allow the article to slide on the track from the first load lock tothe processing chamber when the first device is open. The second devicemay be structured and arranged to allow the article to slide on thetrack from the processing chamber to the second load lock when thesecond device is open.

The first device may be a first rotary barrel gate valve and the seconddevice may be a second rotary barrel gate valve. The system may includea plurality of tracks through the processing chamber and the first andsecond load locks, and all tracks may be angled with respect to thehorizontal. The plurality of tracks may be structured and arranged suchthat articles in each of the plurality of tracks slide thereon under theforce of gravity for simultaneously processing a plurality of articles.The plurality of tracks are typically parallel to one another and theparallel tracks of the first load lock, the tracks of the processingchamber, and the tracks of the second load lock are aligned with oneanother.

The system may include an input tray disposed adjacent the first loadlock. An output tray may be disposed adjacent the output load lock. Theprocessing chamber may be a vacuum sputtering chamber. The first loadlock and the second load lock may be structured and arranged for ventingfrom a first pressure to a second pressure. The first pressure may be avacuum and the second pressure may be atmospheric pressure. The firstload lock and the second load lock may be structured and arranged forevacuating from a first pressure to a second pressure. The firstpressure may be atmospheric pressure and the second pressure may be avacuum. The system may include a third device between the first loadlock and atmosphere and a fourth device between the second load lock andatmosphere. The third device may be a third rotary barrel gate valve andthe fourth device may be a fourth rotary barrel gate valve. The articleto be processed may be any sputterable part such as plastic,polystyrene, and in particular it may be polystyrene plastic cutlery.The system may further include a take-out robot for transferringarticles from an injection molding machine to the input tray. The firstload lock, the second load lock, the first device, the second device andthe processing chamber may be sequenced such that sets of articles maybe processed simultaneously. Each of the processing chamber, the firstand second load locks and the first and second devices may be angledwith respect to the horizontal. The first device may include a body, atleast one passage through the body defining an inlet and an outlet, afirst actuator for rotating the body, a second actuator for translatingthe body, and a sealing portion on the body for sealing the body withrespect to an opening into a chamber adjacent the body.

This invention further features a gravity-fed in-line continuousprocessing system including at least one processing chamber disposedbetween a first load lock and a second load lock, the second load lockdisposed lower than the first load lock, a first device for isolatingthe processing chamber from the first load lock and a second device forisolating the processing chamber from the second load lock. Theprocessing chamber, the first load lock, the second load lock, the firstdevice and the second device may all be angled with respect to thehorizontal, each having a plurality of tracks with the plurality oftracks structured and arranged such that a plurality of articles slidethereon under the force of gravity from the first load lock, through theprocessing chamber, and to the second load lock.

This invention further features a gravity-fed in-line continuousprocessing system including at least one vacuum sputtering chamberdisposed between a first load lock and a second load lock, the secondload lock disposed lower than the first load lock. A first rotary barrelgate valve for isolating the vacuum sputtering chamber from the firstload lock may be included, the first rotary barrel gate valve structuredand arranged to prevent an article from sliding under the force ofgravity when the first rotary barrel gate valve is closed and to allowthe article to slide therethrough under the force of gravity when thefirst rotary barrel gate valve is open. A second rotary barrel gatevalve for isolating the vacuum sputtering chamber from the second loadlock may be included, the second rotary barrel rotary barrel gate valvestructured and arranged to prevent an article from sliding under theforce of gravity when the second rotary barrel gate valve is closed andto allow the article to slide therethrough under the force of gravitywhen the second rotary barrel gate valve is open.

This invention also features a gravity-fed in-line continuous processingsystem including at least one processing chamber disposed between afirst load lock and a second load lock, the second load lock disposedlower than the first load lock. There may be included a first rotarybarrel gate valve for isolating the processing chamber from the firstload lock, the first rotary gate valve structured and arranged toprevent an article from sliding under the force of gravity when thefirst rotary gate valve is closed and to allow the article to slidetherethrough under the force of gravity when the first rotary gate valveis open. There may be included a a second rotary barrel gate valve forisolating the processing chamber from the second load lock, the secondrotary gate valve structured and arranged to prevent the article fromsliding under the force of gravity when the second rotary gate valve isclosed and to allow the article to slide therethrough under the force ofgravity when the second rotary gate valve is open. There may further beincluded a third rotary barrel gate valve for isolating the first loadlock from atmosphere, the third rotary gate valve structured andarranged to prevent the article from sliding under the force of gravitywhen the third rotary gate valve is closed and to allow the article toslide therethrough under the force of gravity when the third rotary gatevalve is open. An input tray may terminate at the third rotary barrelgate valve. A fourth rotary barrel gate valve may be included forisolating the second load lock from atmosphere, the fourth rotary gatevalve structured and arranged to prevent the article from sliding underthe force of gravity when the fourth rotary gate valve is closed and toallow the article to slide therethrough under the force of gravity whenthe fourth rotary gate valve is open. An output tray may be adjacent thefourth rotary barrel gate valve, and a plurality of tracks may be angledthrough the first load lock, the processing chamber, and the second loadlock interconnecting the input tray and the output tray to urge, underthe force of gravity, articles through the first load lock, theprocessing chamber, and the second load lock.

This invention also features a gravity-fed in-line continuous processingsystem including at least one processing chamber module disposed betweena first load lock module and a second load lock module, the second loadlock module disposed lower than the first load lock module. A firstdevice may be included for isolating the processing chamber module fromthe first load lock module, a second device may be included forisolating the processing chamber module from the second load lockmodule, and there may be at least one track through the processingchamber module and the first and second load lock modules, the trackstructured and arranged such that an article slides thereon under theforce of gravity.

This invention further features a gravity-fed in-line continuousprocessing system including at least one processing chamber including atleast one track therethrough, with the track structured and arrangedsuch that an article slides thereon under the force of gravity. Theprocessing chamber may be angled with respect to the horizontal and theat least one track may be angled with respect to the horizontal.

This invention further features a gravity-fed in-line continuousprocessing system including means for processing disposed between afirst means for alternating between a first pressure and a secondpressure, and a second means for alternating between a first pressureand a second pressure. The first pressure may be atmospheric pressureand the second pressure may be a vacuum. Alternatively, the firstpressure may be a vacuum and the second pressure may be atmosphericpressure. The second means for alternating may be disposed lower thanthe first means for alternating. There may be a first means forisolating the means for processing from the first means for alternatingand a second means for isolating the means for processing from thesecond means for alternating. The system may further include at leastone track through the means for processing and the first and secondmeans for alternating. The track may be structured and arranged suchthat an article slides thereon under the force of gravity.

This invention further features a gravity-fed in-line continuousprocessing system including at least one means for processing disposedbetween a first means for alternating between a first pressure and asecond pressure, and a second means for alternating between a firstpressure and a second pressure. The first pressure may be atmosphericpressure and the second pressure a vacuum. The second means foralternating may be disposed lower than the first means for alternating.There may be a first means for isolating the means for processing fromthe first means for alternating. The first means for isolating may bestructured and arranged to prevent an article from sliding under theforce of gravity when the first means for isolating is closed, and toallow the article to slide therethrough under the force of gravity whenthe first means for isolating is open. There may also be a second meansfor isolating the means for processing from the second means foralternating. The second means for isolating may be structured andarranged to prevent the article from sliding under the force of gravitywhen the second means for isolating is closed and to allow the articleto slide therethrough under the force of gravity when the means forisolating is open. There may be a third means for isolating the firstmeans for alternating from atmosphere. The third means for isolating maybe structured and arranged to prevent the article from sliding under theforce of gravity when the third means for isolating is closed, and toallow the article to slide therethrough under the force of gravity whenthe third means for isolating is open. An input tray may terminate atthe third means for isolating. A fourth means for isolating may isolatethe second means for alternating from atmosphere. The fourth means forisolating may be structured and arranged to prevent the article fromsliding under the force of gravity when the fourth means for isolatingis closed, and to allow the article to slide therethrough under theforce of gravity when the fourth means for isolating is open. An outputtray may be adjacent the fourth means for isolating. A plurality oftracks may be angled through the means for alternating, the means forprocessing, and the second means for alternating interconnecting theinput tray and the output tray to urge, under the force of gravity,articles through the first means for alternating, the means forprocessing, and the second means for alternating.

This invention also features a gravity-fed in-line continuous processingsystem including at least one processing chamber isolatable with respectto first and second chambers and means for urging an article from thefirst chamber, through the processing chamber, and to the second chamberunder the force of gravity.

This invention further features a method for coating substrates, themethod comprising providing at least one processing chamber anddisposing the processing chamber between a first load lock and a secondload lock. The second load lock may be disposed lower than the firstload lock. The method further includes isolating the processing chamberfrom the first load lock with a first device, isolating the processingchamber from the second load lock with a second device, and providing atleast one track through the processing chamber and the first and secondload locks and structuring and arranging the track such that an articleslides thereon under the force of gravity. The method may furtherinclude the step of angling the processing chamber, the first load lockand the second load lock with respect to the horizontal. The angle withrespect to the horizontal may be greater than 330 but less than 43°. Theangle with respect to the horizontal may be about 40°. The method mayfurther include angling the at least one track with respect to thehorizontal. The first load lock may be an input load lock and the secondload lock may be an output load lock. The step of isolating theprocessing chamber from the first load lock may be carried out by afirst device, and the step of isolating the processing chamber from thesecond load lock may be carried out by a second device. The first andsecond devices may be rotary barrel gate valves.

The method may further include structuring and arranging the firstdevice and the second device to prevent the article from sliding underthe force of gravity when the first device is closed. The method of thisinvention may further include structuring and arranging the first andsecond devices to allow the article to slide on the track from the firstload lock to the processing chamber when the first device is open. Thefirst device may be a first rotary barrel gate valve and the seconddevice may be a second rotary barrel gate valve. The method may furtherinclude the steps of providing a plurality of tracks through theprocessing chamber and the first and second load locks, angling alltracks with respect to the horizontal, and structuring and arrangingeach of the plurality of tracks such that articles in each of theplurality of tracks slide thereon under the force of gravity forsimultaneously processing a plurality of articles. The plurality oftracks may be parallel to one another. The method may further includethe steps of aligning the parallel tracks of the first load lock, thetracks of the processing chamber, and the tracks of the second load lockwith one another, disposing an input tray adjacent the first load lock,and disposing an output tray adjacent the output load lock. The methodmay further include structuring and arranging the first load lock andthe second load lock for alternating between a first pressure and asecond pressure. The first pressure may be a vacuum and the secondpressure may be atmospheric pressure. The method may also includeproviding a third device between the first load lock and atmosphere anda fourth device between the second load lock and atmosphere, where thethird device is a third rotary barrel gate valve and the fourth deviceis a fourth rotary barrel gate valve. The method further includesequencing the first load lock, the second load lock, the first device,the second device and the processing chamber such that sets of articlesmay be processed simultaneously.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects, features and advantages will occur to those skilled inthe art from the following description of a preferred embodiment and theaccompanying drawings, in which:

FIG. 1 is a schematic side view of one preferred embodiment of thegravity-fed in-line continuous processing system of this invention;

FIG. 2 is a schematic cross-sectional side view of the load locks andprocessing chamber of the system shown in FIG. 1;

FIG. 3 is a schematic cross-sectional side view of rotary barrel gatevalves useful in connection with the gravity-fed in-line continuousprocessing system of this invention;

FIG. 4 is a schematic top view of a gravity-fed in-line continuousprocessing system in accordance with the present invention showing thetracks of each section;

FIG. 5 is a three-dimensional view of tracks useful in accordance withthe present invention;

FIG. 6 is a schematic side view of the gravity-fed in-line continuousprocessing system shown in FIG. 1 in conjunction with an injectionmolding machine and a take-out robot;

FIGS. 7A and 7B are a sequencing chart showing cycle times andsequencing for the system shown FIG. 6;

FIG. 8 is a schematic three-dimensional front view of a gravity-fedin-line continuous processing system of this invention;

FIG. 9 is a schematic cross-sectional side view of one embodiment of arotary barrel gate valve for use with the system of this invention;

FIG. 10 is a schematic side view of one portion of the rotary barrelgate valve of FIG. 9;

FIG. 11 is a schematic cross-sectional view of the rotary barrel gatevalve of FIG. 9 shown in the open position;

FIG. 12 is a schematic cross-sectional view of a rotary barrel gatevalve of FIG. 9 shown in the closed position;

FIG. 13 is an enlarged schematic cross-sectional side view of thesealing portion of the rotary barrel gate valve;

FIG. 14 is a schematic cross-sectional view of an actuator fortranslating the rotary barrel gate valve; and

FIG. 15 is a schematic cross-sectional view of an actuator for rotatingthe rotary barrel gate valve.

DISCLOSURE OF THE PREFERRED EMBODIMENT

Aside from the preferred embodiment or embodiments disclosed below, thisinvention is capable of other embodiments and of being practiced orbeing carried out in various ways. Thus, it is to be understood that theinvention is not limited in its application to the details ofconstruction and the arrangements of components set forth in thefollowing description or illustrated in the drawings.

One gravity-fed in-line continuous processing system in accordance withthe present invention is shown in FIG. 1. The system is comprised ofmodules, for example, a first load lock with gate valves module, aprocessing chamber module, and a second load lock with gate valvesmodule. Parts for processing proceed from one module to another moduleby gravity, with the parts guided individually in tracks or chutes.Load-locks with rotary barrel gate valves preferably function as sealingmechanisms and as part escapements, controlling the flow of parts fromone machine module to the next.

One embodiment of this invention system 10, FIG. 1 includes at least onemeans for processing, such as processing chamber or module 12.Processing chamber 12 is disposed between first means for alternatingbetween a first and a second pressure, such as first load lock or module14, and second means for alternating between a first and a secondpressure, such as second load lock or module 16, with second load lock16 disposed lower than first load lock 14. In accordance with apreferred embodiment of this invention, first load lock 14 is an inputload lock, and second load lock 16 is an output load lock, as shown inFIGS. 1 and 2. As it is known in the art, load lock pressure alternatesfrom high pressure to low pressure and vice versa, depending on thestage in a process.

Any combination of processing chamber modules and a load lock modulesmay be used with the system of the subject invention, thus providingflexibility for the system user. For example, the system may include aseries of load locks and processing chambers in order to end up with athicker part coating than could be achieved with only one processingchamber and using conventional coating methods.

System 10, FIG. 1 further includes first means for isolating, such asfirst device 18, for isolating processing chamber 12 from first loadlock 14, and second means for isolating, such as second device 20, forisolating processing chamber 12 from second load lock 16. First loadlock 14 and second load lock 16 are structured and arranged for ventingor evacuating from a first to a second pressure by venting or evacuatingload locks 14 and 16, from a vacuum to ambient atmospheric pressure andvice versa in one example, using known methods. For example, whenarticle 24 is in first load lock 14 at ambient atmosphere, beforearticle 24 can enter into processing chamber 12, first load lock 14 isevacuated. Then later, before first load lock can be opened to allow inthe next article, load lock 14 must be vented.

System 10 includes at least one track or chute 22 through at least oneof processing chamber 12 and first and second load locks 14 and 16, withtrack 22 structured and arranged such that article or part 24 slides ontrack 22 under the force of gravity. Track 22 is shown in phantomcross-section and in exemplary fashion in first load lock 14 of FIG. 1.At least one of processing chamber 12, first load lock 14, second loadlock 16, first device 18 and second device 20, is angled with respect tohorizontal 19. Alternatively or additionally, track 22 may be angledwith respect to horizontal 19. In one embodiment system 10 is designedfor coating plastic flatware or cutlery, and angle 26 is greater thanabout 32° but less than about 44°. In one embodiment for coating plasticflatware, angle 26 is about 40°. Optimum angles for various coatingprocesses, such as coating phone carriers, or for tracks or chutes thatinclude bearings, are possible with system 10. It can be seen that acombination of angling track 22 and modules 12, 14 and/or 16 withrespect to the horizontal can achieve a desired angle for the system.Track or chute 22 is structured and arranged so that part 24 will slideunder its own weight, eliminating the need for complex conveyors androbotic arms within the system, thus improving overall system mechanicaland operational reliability. There is typically one part 24 per chute 22within any particular module, although there may be many chutes withinany particular module, as well as sets of articles passing through thesystem at one time as described below with respect to sequencing of thesystem.

In one embodiment, processing chamber 12 is a vacuum sputtering chamberincluding a cathode and shield assembly for metallization on at leastone side of article 24 as is known to those skilled in the art, althoughthe processing chamber 12 of this invention is not limited to a vacuumsputtering chamber or to a particular coating or to coating on one sideonly. Article 24 to be coated may be any sputterable part, such asplastic or polystyrene. The present invention has been successfully usedto coat or metallize polysterene plastic cutlery, such as spoons, knivesand forks, with stainless steel. The system of the present invention mayfurther include input tray 40 and output tray 42 as shown in FIG. 1.

When first device 18 is closed, FIG. 3, first device 18 is structuredand arranged to prevent article 24(1) from sliding under the force ofgravity. Similarly, when second device 20 is closed, second device 20 isstructured and arranged to prevent article 24(2) from sliding under theforce of gravity (not shown). Conversely, when second device 20 is open,second device 20 is structured and arranged to allow article 24(2) toslide under the force of gravity on track 22 through second device 20and into the next chamber or to atmosphere. Similarly, when first device18 is open, first device 18 is structured and arranged to allow article24(1) to slide on track 22 through first device 18 and into the nextchamber or to atmosphere (not shown). Part gate 29, FIG. 2 keeps article24 from sliding within processing chamber 12. Part gate 29 may be usedat any point or in any module of the system, even in addition to thearticle stopping function of first and second devices 18 and 20.

In one preferred embodiment, first and second devices 18 and 20 arerotary barrel gate valves as shown in FIGS. 2 and 3. First and seconddevices 18 and 20, i.e. rotary barrel gate valves 18 and 20, are used toopen and close first and second load locks 14 and 16 to either theatmosphere or to processing chamber 12. For example, a mechanicalroughing pump may be used to evacuate first load lock 14 from a firstpressure, typically atmosphere, prior to transferring part 24 from firstload lock 14 into processing chamber 12 which is at a second pressure,typically a vacuum.

First and second devices 18 and 20 (i.e. rotary barrel gate valves)operate with long durability and with high reliability. Each gate valveis interlocked or sequenced to detect full closure, minimizing the riskof direct passing of atmosphere into processing chamber 12, for example,should part 24 become lodged in a gate valve. If part 24 does get lodgedin this manner, system 10 halts and an error condition is reportedindicating the reason for the error.

In accordance with one embodiment of the present invention, system 10may include third device 18′, FIGS. 1 and 2 between first load lock 14and atmosphere, and fourth device 20′ between second load lock 16 andatmosphere, where atmosphere is atmospheric pressure. Third and fourthdevices 18′ and 20′ may be rotary barrel gate valves similar to firstand second devices 18 and 20.

Each of processing chamber 12, first and second load locks 14, 16, andfirst and second devices 18, 20 may include at least one track 22. Eachof processing chamber 12, first and second load locks 14 and 16, andfirst and second devices 18 and 20 may include a plurality of tracks 22a,22 b . . . 22 n, FIG. 4. In one example, plurality of tracks 22 a, 22b . . . 22 n are angled with the horizontal in like manner as singletrack 22 in FIG. 1. The plurality of tracks 22 a, 22 b . . . 22 n arestructured and arranged such that articles 24 a, 24 b . . . 24 n in eachof plurality of tracks 22 a, 22 b . . . 22 n slide therein under theforce of gravity for simultaneous processing.

Tracks 22 a, 22 b . . . 22 n of first load lock 14, correspondingtracks, i.e. 22 a′, 22 b′ . . . 22 n′ of processing chamber 12 andcorresponding tracks i.e. 22 a″, 22 b″. . . 22 n″ of second load lock 16are aligned with one another. Each of tracks 22 a, 22 b . . . 22 n, areparallel to one another, as are each of tracks 22 a′, 22 b′ . . . 22 n′and each of tracks 22 a″, 22 b″ . . . 22 n″. The parallel layout of thetracks permits more tracks to be added by adding width to system 10, andby adding length to the first and second devices 18, 20 (and third andfourth devices 18′, 20′) where, as noted above, both first and seconddevices 18, 20 also include tracks, i.e. 22 a″″, 22 b″″ . . . 22 n″″(not shown) corresponding to and aligned with tracks of adjacent loadlocks or processing chamber.

Tracks 22 a, 22 b . . . 22 n are arranged in groups 70, 72, 74, 76. . .with members 80, 82, 84 . . . 84 n installed between groups to providestructural support, as exemplified by FIG. 5 showing the tracks of inputtray 40. In one embodiment, members 80 and tracks 22 a, 22 b . . . 22 nare machined from one solid sheet of aluminum. Input tray 40 includestracks, i.e. 22 a′″, 22 b′″ . . . 22 n′″ corresponding to the tracks 22a, 22 b . . . 22 n . . . of input load lock 14, tracks 22 a′, 22 b′ . .. 22 n′ of processing chamber 12, tracks 22 a″, 22 b″ . . . 22 n″ ofoutput load lock 16 as shown in FIG. 4, and so on with respect to thetracks of first and second devices 18, 20 and output tray 42 (notshown).

Those skilled in the art will recognize that a system in accordance withthe present invention may be comprised of processing chamber 12 aloneincluding at least one track, if contamination during processing is nota concern. In such a case, processing chamber 12 may be angled withrespect to the horizontal, or track 22 may be angled with respect to thehorizontal, or both processing chamber 12 and track 22 may be angledwith the horizontal.

Gravity-fed in-line continuous processing system 10 of this invention,FIG. 6 may be used stand-alone, or it may include interface 50 withinjection molding machine 52, with interface 50 being an electricalhandshake scheme as is known in the art. The system may further includetake-out robot 54 for transferring parts or articles 24 a, 24 b . . . 24n, FIG. 4 from injection molding machine 52 to input tray 40, FIG. 6.Parts 24 a, 24 b . . . 24 n are loaded onto input tray 40 by take outrobot 54. Input tray 40 may accept parts from take out robot 54 andlaterally shift parts 24 to align them to tracks 22 a, 22 b . . . 22 n.Optical systems can be used to determine if the tray is full.

Applying a metal coating to a clear polystyrene cutlery, for example, bymetallization, can be accomplished in a vastly improved manner utilizingthis invention. The invention assures high quality, high adhesion, andan overall more robust process.

The operation of system 10 and method of the invention is described asfollows. Freshly molded parts or articles 24 a, 24 b . . . 24 n (notshown) are placed on input tray 40 by takeout robot 54, FIG. 6. In oneexample of this invention, forty parts (e.g. 24 a, 24 b . . . 24 n wherepart 24 n is the fortieth part 24 ₄₀) are transferred at one time frominput tray 40 into first or input load lock 14 through rotary barrelgate valve 18′. Thereafter air is evacuated from input load lock 14.From input load lock 14 parts 24 a, 24 b . . . . 24 n are transferredthrough rotary barrel gate valve 18 into processing or sputteringchamber 12 where they are sputtered or coated. In this example, parts 24a, 24 b . . . 24 n are thereafter transferred through rotary barrel gatevalve 20 into second or output load lock 16. Output load lock 16 is thenvented to atmospheric pressure, and parts 24 a, 24 b . . . 24 n arethereafter transferred through rotary barrel gate valve 20′ to outputtray 42 where parts 24 a, 24 b . . . 24 n may be transferred into boxes60 for shipping. The entire machine cycle may take place in seconds, incontrast to current systems which take much longer. The subjectinvention thus results in an improved, more rapid, gravity-fed in-linecontinuous processing system.

Notably, in accordance with the present invention, all portions ofsystem 10, namely rotary barrel gate valve 18′, input load lock 14,rotary barrel gate valve 18, processing chamber 12, rotary barrel gatevalve 20, output load lock 16, and rotary barrel gate valve 20′ areinterlocked or sequenced such that sets of articles may be processedsimultaneously. This makes the system more efficient and continuous.

Particularly, one sequence for use in system 10 is shown in FIGS. 7A and7B, where “A” is rotary barrel gate valve 18′ of FIG. 6, “B” is rotarybarrel gate valve 18, “C” is rotary barrel gate valve 20, and “D” isrotary barrel gate valve 20′. One “day” in FIGS. 7A and 7B is equivalentto 100 milliseconds. Input load lock 14 and output load lock 16 aresignified by “ILL” and “OLL” in FIGS. 7A and 7B. In FIGS. 7A and 7B,reference numerals 300 a . . . 300 n each represent one set of parts orarticles 24 a, 24 b . . . 24 n through system 10. First set 300 arepresents the first set of parts or articles to go through the system,and 300 b represents a second set of parts to go through the system. Thestart of second set of parts 300 b is determined by the existence ofproper conditions downstream in system 10. For example, opening ofrotary barrel gate valve 18′ for second set of parts 300 b is determinedby proper completion of the load lock cycle for first set of parts 300a. Controller 90, FIG. 6 controls the sequencing of the system usingstandard customizable software, such as Ladder Logic, which is standardfor use with automatic Programmable Logic Controllers (PLCs).

In one example, the opening of rotary barrel gate valve 18′, FIG. 6 forthe start of a second cycle 302, FIGS. 7A and 7B of parts begins whenfirst set of parts 300 a are being processed or sputtered 304 inprocessing chamber 12, FIG. 6. As shown in FIGS. 6, 7A and 7B, at thatpoint in time, rotary barrel gate valve 18′ is opened (unsealed) toallow second set of parts 300 b to slide through into input load lock14. Input load lock 14 is sealed by closing rotary barrel gate valve18′. Input load lock 14 is evacuated from atmospheric pressure ofapproximately 760 Torr to vacuum pressure of approximately 250milliTorr. Rotary barrel gate valve 18 is opened and first set of parts300 a slides into chamber 12. Rotary barrel gate valve 18 is thenclosed, input load lock 14 is vented to atmospheric pressure, and firstset of parts 300 a is sputtered. During this time, rotary barrel gatevalve 18′ opens again and second set of parts 300 b enters input loadlock 14. Rotary barrel gate valve 18′ closes and seals, and rotarybarrel gate valve 20 is opened while input load lock 14 (with second setof parts 300 b) is being evacuated. First set of parts 300 a slide fromprocessing chamber 12 to output load lock 16. When input load lock 14 isevacuated, output load lock 16 is vented to atmosphere. Second set ofparts 300 b thereafter slides from input load lock 14 into processingchamber 12 after rotary barrel gate valve 18 opens. First set of parts300 a slides from output load lock 16 to an optional output tray afterrotary barrel gate valve 20′ opens. This sequence continues and repeatsitself for any number of desired cycles or sets of parts 300 a . . . 300n. In one embodiment, the direction of sealing of rotary gate valves 18and 20, FIG. 6 is such that the sealing of chamber 12 occurs at points80, 82, 84, 86 in order to take advantage of pressure assisted sealing.Pressure assisted sealing is desirable for longer rotary barrel gatevalves 18′, 18, 20, 20′ where there is deflection of the rotary barrelgate valves due to their length. Sealing points 80, 82, 84 and 86 resultin load locks 14 and 16 having larger volumes. In other embodimentswhere pressure assisted sealing is less important or not desired, suchas embodiments with short rotary barrel gate valves 18′, 18, 20, 20′,sealing of chamber 12 could occur at points 85 and 87 instead of or inaddition to points 82 and 84, for example. This would result in loadlocks 14 and 16 having smaller volumes, which may be desirable in someapplications of system 10.

The sequence just described is for system 10, FIG. 6 using a thincoating metallizer for processing chamber 12 and using only one vacuumpump for both first and second load locks 14 and 16. It will be apparentto one skilled in the art that the sequencing may be adjusted toaccommodate various processing times, any number of chambers and loadlocks, and for any number of vacuum pumps used with the system.

A schematic three-dimensional representation of system 10 of thisinvention, without take out robot or output tray, is shown in FIG. 8.

For system 10 of this invention, it is useful to use first, second,third and fourth devices 18, 18′, 20′, 20, FIG. 6 which are rotarybarrel gate valves, represented as rotary barrel gate valve 100 in FIGS.9-13.

Rotary barrel gate valve 100 includes body 102, FIGS. 9 and 10 and atleast one passage 104 through body 102 defining inlet 106 and outlet108. Means for rotating body 102, such as actuator 110, rotates body 102about its axis 105, i.e. in the directions of arrow 111. Means fortranslating or moving body 102, such as actuator 112, translates ormoves body 102 approximately linearly, i.e. in the directions of arrow113. Means for sealing, such as sealing portion 116 on body 102, FIG. 10is for sealing body 102 with respect to an opening into a chamberadjacent body 102 (adjacent chamber not shown). In one example, body 102is cylindrical and solid, and passage 104 through body 102 has ancircular shape. If rotary barrel gate valve 100 is adjacent a vacuumchamber, body 102 is typically surrounded by housing 129 as shown inFIG. 9. Body 102, however, could be hollow and passage 104 could be inthe form of a track interconnecting an inlet and an outlet as shown inFIG. 10.

Passage 104 includes at least one track or chute 120. In one embodiment,a plurality of passages 104, 104 a . . . 104 n define a plurality ofinlets 106, 106 a . . . 106 n and outlets 108, 108 a . . . 108 n. Eachof the plurality of passages 104, 104 a . . . 104 n includes at leastone track or chute 120 therein, and each passage 104, 104 a . . . 104 nincludes a plurality of tracks or chutes 120, 120 _(a) . . . 120 _(n),120 a _(a), 120 a _(b) . . . 120 a _(n), . . . 120 n _(a), 120 n _(b) .. . 120 n _(n). Such an embodiment also includes a plurality of sealingportions 116, 116 a . . . 116 n, FIG. 10. By adding length andadditional passages, rotary barrel gate valve 100 of this invention isscalable. This results in decreased cost to add to system capacity,because adding length and increasing the number of passages 104 to body102 does not require any significant changes to actuator 110 or 112.

In one embodiment, sealing portion 116, FIG. 10 which may be anywhere onbody 102, is O-ring 130 disposed in groove 132 formed on surface 138 ofbody 102. In one preferred embodiment, body 102 will have passage 104corresponding to sealing portion 116 such that when body 102 is rotatedas indicated by arrow 111, passage 104 and sealing portion 116 willalternately be aligned with an opening into a chamber adjacent the body(not shown). In other embodiments, O-ring 130 may instead be locatedabout the opening into an adjacent chamber (not shown). In eitherembodiment, the O-ring pushes on and off the sealing surface, maximizingthe life of the surface of the O-ring.

When rotary barrel gate valve 100 is open, FIG. 11 inlet 106 in passage104 of body 102 is aligned with opening 140 of chamber 12, allowingarticle 24, for example, to move from chamber 12 to output load lock 16.Controller 300 may be included for interlocking or sequencing each gatevalve 100 with any other gate valves in accordance with system 10 todetect full closure and to allow for processing of a plurality ofarticles simultaneously in one track. Thus, for instance, the risk ofdirect passing of atmosphere into a processing chamber 12 is minimizedshould an article become lodged in any gate valve. In such an event,system 10 halts and an error condition is reported. Also, sequencing ofmultiple rotary barrel gate valves increases productivity.

Rotary barrel gate valve 100 is moved from closed, FIG. 12, to open,FIG. 11, and vice versa, by actuators 110 and 112, FIG. 9. When rotarybarrel gate valve 100 is open as in FIG. 11, inlet 106 is aligned withopening 140 into chamber 12. Passage 104 now provides access throughrotary barrel gate valve 100 out of chamber 12. To close rotary barrelgate valve 100, actuator 110, FIG. 9 rotates body 102 in the directionof arrow 150, FIG. 11 to align sealing portion 116 with opening 140.Now, passage 104, FIG. 12 is not aligned with opening 140. Immediatelythereafter, actuator 112, FIG. 9 moves or translates sealing portion 116in the direction of arrow 152 and against opening 140. Then, to openrotary barrel gate valve 100, actuator 112 moves sealing portion 116 inthe direction of arrow 154 and immediately thereafter actuator 110rotates body 102 in the direction of arrow 156 to once again align inlet106 with opening 140 into chamber 12.

When rotary barrel gate valve 100 is closed, FIG. 13 groove 132 islocated in opposing flats 134, 136 formed on surface 138 of body 102. Inone embodiment, portion or nose piece 142 of body 102 projects betweenopposing flats 134, 136 and may have a curvature to form articlestopping surface or escapement 144 for stopping article 24, for example,from output load lock 16 to atmosphere. Conversely, when rotary barrelgate valve 100 is open, portion 142 of body 102 no longer forms articlestopping surface 144. In one embodiment of system 10, article stoppingsurface 144 formed by portion 142 is used only in rotary barrel gatevalve 20′, FIG. 1, with backs 60, 62, and 64 of rotary barrel gatevalves 18, 18′ and 20 serving to stop article 24. Whether by articlestopping surface 144 or by backs 60, 62, 64, rotary barrel gate valves18′, 18, 20, 20′ are structured and arranged to prevent article 24 fromsliding under the force of gravity when closed.

As described herein, a “chamber” could be an input load lock or anoutput load lock or atmosphere, and the term “chamber” as used herein isnot necessarily limited to a processing chamber. For example, in FIG.12, rotary barrel gate valve 100 seals chamber 12, e.g. a processingchamber, with respect to output load lock 16. However, in anotherexample, rotary barrel gate valve 18′, FIG. 1 seals input load lock“chamber” 14 from atmosphere.

For use with rotary barrel gate valve 100 actuator 110, FIG. 14 may be apneumatic rotary actuator or a cam rotary actuator. In one embodiment,actuator 110 is a servo motor connected to body 102 for rotating body102. Actuator 110 alternately rotates body 102 to align sealing portion116, FIGS. 12 and 13 with, for example, opening 140 into chamber 12, andto align passage 104 with opening 140 into chamber 12. Actuator 112,FIG. 15 is typically a pneumatic cylinder 200. When activated, pneumaticcylinder 200 of actuator 112 projects (or retracts) push pin 202 whichcauses body 102 to pivot around pivot point 204 in the directions ofarrow 206, thus urging or translating body 102 approximately linearly,for example, toward and away from chamber 12, as shown in FIGS. 12 and13. In this embodiment, body 102 moves approximately linearly but in avery slight arc. Actuator 112 may utilize a lead screw or othermechanical device for linear translation (not shown). The servo motorand the short stroke of actuator 112 permit very fast gate valve openingand closing times.

As noted, the number of chambers or modules of system 10 in accordancewith this invention may be increased or decreased and articles otherthan plastic cutlery may be coated. Other types of processing chambersmay be used or added to the system. Also, other types of load and unloadlocks may be used.

Although specific features of the invention are shown in some drawingsand not in others, this is for convenience only as each feature may becombined with any or all of the other features in accordance with theinvention. The words “including”, “comprising”, “having”, and “with” asused herein are to be interpreted broadly and comprehensively and arenot limited to any physical interconnection. Moreover, any embodimentsdisclosed in the subject application are not to be taken as the onlypossible embodiments.

Other embodiments will occur to those skilled in the art and are withinthe following claims:

1. A gravity-fed in-line continuous processing system comprising: atleast one processing chamber disposed between a first load lock and asecond load lock, the second load lock disposed lower than the firstload lock; a first device including a body for isolating the processingchamber from the first load lock; a second device for isolating theprocessing chamber from the second load lock; at least one track throughthe processing chamber and the first and second load locks, the trackstructured and arranged such that an article slides thereon under theforce of gravity; and at least one passage through the body defining aninlet and an outlet, a first actuator for rotating the body, a secondactuator for translating the body, and a sealing portion on the body forsealing the body with respect to an opening into a chamber adjacent thebody.
 2. A gravity-fed in-line continuous processing system comprising:at least one processing chamber disposed between a first load lock and asecond load lock, the second load lock disposed lower than the firstload lock; a first device including a body for isolating the processingchamber from the first load lock; a second device for isolating theprocessing chamber from the second load lock; at least one track throughthe processing chamber and the first and second load locks, the trackstructured and arranged such that an article slides thereon under theforce of gravity; and a plurality of passages through the body defininga plurality of inlets and outlets, a first actuator for rotating thebody, a second actuator for translating the body, and a plurality ofsealing portions on the body, the plurality of sealing portionscorresponding to each of the passages for sealing the body with respectto openings into a chamber adjacent the body.